Heating element and fluid heater and method for heating a fluid

Abstract

A heating element for an electric fluid heater, the heating element having an extension along a first axis and comprising fluid permeable heating panels extending at an angle within a range of 45-90 degrees to the first axis and being arranged adjacent to each other along the first axis with an interspace between adjacent heating panels. Each heating panel comprises a 3-dimensional structure, the 3-dimensional structure comprising a multitude of members of at least one electrically conductive material. The heating element has a 3-dimensional shape which is delimited in part by a first lateral side and an opposite second lateral side. The heating panels are electrically connected in series via electrical connectors arranged at the first and second lateral sides. The 3-dimensional structure comprises at least three members arranged after each other along the first axis and connected to each other at nodes.

1 . A heating element for an electric fluid heater, the heating element having an extension along a first axis and comprising fluid permeable heating panels extending at an angle within a range of 45-90 degrees to the first axis and being arranged adjacent to each other along the first axis with an interspace between adjacent heating panels,
 wherein each heating panel comprises a 3-dimensional structure, the 3-dimensional structure comprising a multitude of members of at least one electrically conductive material,   wherein the heating element has a 3-dimensional shape which is delimited in part by a first lateral side and an opposite second lateral side, the first and second lateral sides extending substantially in parallel with the first axis and the heating panels extending between the first and second lateral sides,   wherein the heating panels are electrically connected in series via electrical connectors arranged at the first and second lateral sides, and   wherein the 3-dimensional structure comprises at least three members arranged after each other along the first axis and connected to each other at nodes.   
     
     
         2 . The heating element according to  claim 1 , wherein an electrically conductive path is provided through the heating element by the heating panels and the electrical connectors, wherein the heating element has a length along the first axis, and wherein the electrically conductive path is longer than the length along the first axis. 
     
     
         3 . The heating element according to  claim 1 , wherein the heating panels are electrically connected in series only via the electrical connectors arranged at the first and second lateral sides. 
     
     
         4 . The heating element according to  claim 1 , wherein each of the heating panels is a result of an additive manufacturing process. 
     
     
         5 . The heating element according to  claim 1 , wherein the electrical connectors are a result of an additive manufacturing process. 
     
     
         6 . The heating element according to  claim 1 , comprising at least 2 heating panels. 
     
     
         7 . The heating element according to  claim 1 , comprising at least two rows of heating panels arranged adjacent to each other along the first axis. 
     
     
         8 . The heating element according to  claim 7 , wherein each of the at least two rows of heating panels comprises at least 2 heating panels. 
     
     
         9 . The heating element according to  claim 7 , wherein the heating panels of the at least two rows of heating panels are electrically connected in series along an electrically conductive path, from a first end portion of the heating element to an opposite second end portion of the heating element seen along the first axis, via the electrical connectors being arranged alternatingly at the first and second lateral sides, and
 wherein some of the electrical connectors extend between adjacent heating panels within a row of heating panels and some of the electrical connectors extend between heating panels of adjacent rows of heating panels.   
     
     
         10 . The heating element according to  claim 1 , wherein a thickness of the members is within a range of 0.05-10 mm, or within a range of 0.1-4 mm, or within a range of 0.2-1 mm, and
 wherein a length of the members is within a range of 0.1-50 mm, or within a range of 0.2-15 mm or within a range of 0.5-5 mm.   
     
     
         11 . The heating element according to  claim 1 , wherein the members are connected at nodes to form a multitude of unit cells. 
     
     
         12 . The heating element according to  claim 1 , comprising electrically non-conductive spacer elements arranged between adjacent heating panels of a row of heating panels at the first and second lateral sides. 
     
     
         13 . The heating element according to  claim 12 , wherein along the first lateral side, one of the electrical connectors extends between two adjacent heating panels to form a pair of heating panels and one of the spacer elements is arranged between the pair of heating panels and a further adjacent heating panel, and
 wherein along the second lateral side, one of the spacer elements is arranged between the two heating panels of the pair of heating panels and one of the electrical connectors extends between one of the heating panels of the pair of heating panels and the further adjacent heating panel.   
     
     
         14 . The heating element according to  claim 1 , wherein the heating element comprises at least two rows of heating panels and at least one electrically non-conductive further spacer element arranged between adjacent heating panels of adjacent rows of heating panels. 
     
     
         15 . The heating element according to  claim 1 , wherein the heating panels are configured to be electrically heated up to a temperature of 1450 degrees Celsius, up to a temperature of 1900 degrees Celsius, or up to a temperature within a range of 1700-1900 degrees Celsius, or up to a temperature within a range of 1600-2000 degrees Celsius. 
     
     
         16 . The heating element according to  claim 1 , wherein a first heating panel differs from a second heating panel by any one or a combination of:
 the 3-dimensional structure;   a cross-sectional area, thickness or width of the members;   a size, shape, or number of voids within the heating panels; and   a length along the first axis of the heating panels.   
     
     
         17 . The heating element according to  claim 1 , wherein the 3-dimensional structure is a self-supporting structure. 
     
     
         18 . An electric fluid heater, comprising:
 at least one heating element according to  claim 1 ; and   a housing having a fluid inlet and a fluid outlet,   wherein a fluid flow path for the fluid to be heated is defined within the housing, and   wherein the at least one heating element is arranged with its first axis extending along at least part of the fluid flow path.   
     
     
         19 . The electric fluid heater according to  claim 18 , comprising an insulation material arranged at least along part of the fluid flow path. 
     
     
         20 . A method for heating a fluid in an electric fluid heater according to  claim 18  comprising steps of:
 supplying a fluid to the fluid inlet; 
 supplying an electric current to the at least one heating element in order to heat the heating panels; 
 conducting the fluid along the fluid flow path through the heating panels to the fluid outlet; and 
 leading the fluid from the fluid outlet.